Honeycomb Filter, and Method for Manufacturing Honeycomb Filter

Abstract

A honeycomb filter comprises a columnar body including inlet-side flow passages (first flow passages) and outlet-side flow passages (second flow passages) extending in an axial direction and including partition walls W separating the adjacent flow passages. A cross-section area of each inlet-side flow passage on one end face of the columnar body is larger than a cross-section area of each inlet-side flow passage in a central part in the axial direction, and a cross-section area of each outlet-side flow passage is closed on the one end face. A corner part C that forms the inlet-side flow passage and is formed between an adjacent pair of partition walls W has a protrusion part (first protrusion part)that protrudes toward an interior of the inlet-side flow passage and extends in the axial direction, in a central part of at least one of the inlet-side flow passages in the axial direction.

Claims

1. A honeycomb filter comprising a columnar body including a plurality of first flow passages and a plurality of second flow passages extending in an axial direction and including partition walls separating the adjacent flow passages, wherein a cross-section area of each first flow passage on one end face of the columnar body is larger than a cross-section area of each first flow passage in a central part in the axial direction, and each second flow passage is closed on the one end face, and a corner part that forms the first flow passage and is formed between an adjacent pair of the partition walls has a first protrusion part that protrudes toward an interior of the first flow passage and extends in the axial direction, in a central part of at least one of the first flow passages in the axial direction.

2. The honeycomb filter according to claim 1, wherein one of the pair of partition walls forming the corner part separates the first flow passage and the second flow passage from each other.

3. The honeycomb filter according to claim 1, wherein a cross-section area of each second flow passage on the other end face of the columnar body is larger than a cross-section area of each second flow passage in the central part in the axial direction, and each first flow passage is closed on the other end face, and a corner part that forms the second flow passage and is formed between an adjacent pair of the partition walls has a second protrusion part that protrudes toward an interior of the second flow passage and extends in the axial direction, in a central part of at least one of the second flow passages in the axial direction.

4. The honeycomb filter according to claim 1, wherein in an axial-directional central part of the columnar body, the first flow passage is adjacent to three of the second flow passages and three of the first flow passages, and the second flow passage is adjacent to six of the first flow passages.

5. The honeycomb filter according to claim 1, wherein in an axial-directional central part of the columnar body, the first flow passage is adjacent to two of the second flow passages and four of the first flow passages, and the second flow passage is adjacent to six of the first flow passages.

6. The honeycomb filter according to claim 1, wherein in an axial-directional central part of the columnar body, the first flow passage is adjacent to four of the second flow passages and four of the first flow passages, and the second flow passage is adjacent to four of the first flow passages.

7. The honeycomb filter according to claim 1, wherein in the central part of at least one of the first flow passages in the axial direction, at least one of the partition walls has a third protrusion part that protrudes toward the interior of the first flow passage or the second flow passage and extends in the axial direction in a central part of the partition wall.

8. A method for manufacturing a honeycomb filter, comprising: a step of preparing a honeycomb compact including a columnar body having a plurality of first flow passages and a plurality of second flow passages extending in an axial direction and having partition walls separating the adjacent flow passages, a corner part that forms the first flow passage and is formed between an adjacent pair of the partition walls having a first protrusion part that protrudes toward an interior of the first flow passage, in a central part of at least one of the first flow passages in the axial direction; and a step of inserting a jig into each first flow passage of the honeycomb compact to enlarge a cross-section area and crimping the partition walls together on each second flow passage side to close each second flow passage.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0022] FIG. 1 is a perspective view of a honeycomb filter according to a first embodiment.

[0023] FIG. 2 is a cross-sectional view of an axial-directional center part of the honeycomb filter taken along the II-II line in FIG. 1.

[0024] FIG. 3 is an expanded view of FIG. 2.

[0025] Portion (a) of FIG. 4 is an expanded view of an inlet-side end face 10E.sub.in in FIG. 1, and portion (b) of FIG. 4 is a cross-sectional view taken along the b-b line in portion (a) of FIG. 4.

[0026] Portion (a) of FIG. 5 is an expanded view of an outlet-side end face 10E.sub.out in FIG. 1, and portion (b) of FIG. 5 is a cross-sectional view taken along the b-b line in portion (a) of FIG. 5.

[0027] FIG. 6 is a schematic diagram showing a method for manufacturing a honeycomb filter according to the first embodiment.

[0028] FIG. 7 is a cross-sectional view of an axial-directional center part of a compact showing a situation where inlet-side flow passages 70H.sub.in of the compact are enlarged to close outlet-side flow passages 70H.sub.out.

[0029] FIG. 8 is a cross-sectional view of an axial-directional center part of a honeycomb filter according to a second embodiment.

[0030] FIG. 9 is an expanded view of the inlet-side end face 10E.sub.in of the honeycomb filter according to the second embodiment.

[0031] FIG. 10 is an expanded view of the outlet-side end face 10E.sub.out in FIG. 1.

[0032] FIG. 11 is a cross-sectional view of an axial-directional center part of a honeycomb filter according to a third embodiment.

[0033] FIG. 12 is an expanded cross-sectional view of an axial-directional center part of a honeycomb filter according to a fourth embodiment.

DESCRIPTION OF EMBODIMENTS

[0034] A first embodiment of the present invention is described with reference to the drawings.

First Embodiment

[0035] A honeycomb filter 100 according to the embodiment includes a cylindrical body 10 as shown in FIG. 1. The cylindrical body 10 has an inlet-side end face 10E.sub.in and an outlet-side end face 10E.sub.out.

[0036] FIG. 2 is a cross-section of a central part CP of the cylindrical body 10 in the axial direction. The cylindrical body 10 has many inlet-side flow passages 70H.sub.in and many outlet-side flow passages 70H.sub.out. In the embodiment, the inlet-side flow passages 70H.sub.in and the outlet-side flow passages 70H.sub.out are regularly arranged in such a way that one inlet-side flow passage 70H.sub.in is adjacent to three other inlet-side flow passages 70H.sub.in and is adjacent to three outlet-side flow passages 70H.sub.out. One outlet-side flow passage 70H.sub.out is adjacent to six inlet-side flow passages 70H.sub.in and is not adjacent to the other outlet-side flow passages 70H.sub.out. Each flow passage is adjacent to totally six flow passages respectively via partition walls.

[0037] FIG. 3 is an expanded view of FIG. 2. Between the adjacent flow passages, the respective partition walls W which separate these are provided, and an aggregate of the partition walls W constitutes the cylindrical body 10.

[0038] The outlet-side flow passage 70H.sub.out is formed of six partition walls W, and its cross-section shape is substantially hexagonal. The inlet-side flow passage 70H.sub.in is formed of six partition walls W. In the inlet-side flow passage 70H.sub.in, in each corner part C made between an adjacent pair of partition walls W, a protrusion part (first protrusion part) WP protruding toward the interior of the inlet-side flow passage 70H.sub.in is formed. Accordingly, the cross-section shape of the inlet-side flow passage 70H.sub.in has a shape in which the vertices of the hexagon are caused to protrude toward the inside. Each protrusion part WP extends in the axial direction of the cylindrical body 10 (flow passages).

[0039] The height of the protrusion part WP is not specially limited but, for example, a protrusion height HT from line L1 connecting both ends of the bottom part of the protrusion part WP can be 0.04 to 0.20 mm. Moreover, when point Q formed by connecting portions of the pair of partition walls W other than the protrusion part, the centroid G of the inlet-side flow passage 70H.sub.in, and intersection S of line L2 connecting the point Q and the centroid G and the outermost part of the protrusion part WP are defined, the distance between the point Q and the intersection S can be set to be 0.1 to 0.3 mm.

[0040] Next, referring to portions (a) and (b) of FIG. 4, an inlet-side structure is presented. On the inlet-side (one end-side) end face 10E.sub.in, the cross-section area of the inlet-side flow passage 70H.sub.in is made larger than that in the central part in the axial direction. On the other hand, the cross-section area of the outlet-side (the other end-side) flow passage 70H.sub.out becomes 0 and is closed. Specifically, the cross-section shape of each inlet-side flow passage 70H.sub.in which is substantially hexagonal in the axial-directional center part as in FIG. 2 is enlarged so as to become triangular, the vertices of each triangle reach the centers of the outlet-side flow passages 70H.sub.out, and in this way, the outlet-side flow passage 70H.sub.out is closed. In other words, the inlet-side flow passage 70H.sub.in has, on the inlet-side end face 10E.sub.in, a tapered part in which the cross-section area becomes larger as going toward the inlet-side end face 10E.sub.in.

[0041] Next, referring to portions (a) and (b) of FIG. 5, an outlet-side structure is presented. On the outlet-side end face 10E.sub.out, the cross-section area of the outlet-side flow passage 70H.sub.out is made larger than that in the central part in the axial direction. On the other hand, the cross-section area of the inlet-side flow passage is made 0 and is closed. Specifically, the cross-section shape of each outlet-side flow passage 70H.sub.out which is substantially hexagonal in the axial-directional center part as in FIG. 2 is enlarged to be hexagonal in such a way that the portions of the sides become corners, the vertices of each hexagon reach the centers of the inlet-side flow passages 70H.sub.in, and in this way, the inlet-side flow passage 70H.sub.in is closed. In other words, the outlet-side flow passage 70H.sub.out has, on the outlet-side end face 10E.sub.out, a tapered part in which the cross-section area becomes larger as going toward the outlet-side end face 10E.sub.out.

[0042] The material of the cylindrical body is porous ceramics. Examples of the ceramics include aluminum titanate, silicon carbide and cordierite. The aluminum titanate can contain magnesium, silicon and the like.

[0043] Such a honeycomb filter can be manufactured by the following method. First, extrusion molding is performed on a ceramic raw material by an extrusion molding machine to manufacture a honeycomb compact having the cross-section shape as in FIG. 2. The honeycomb compact has unclosed inlet-side flow passages 70H.sub.in and unclosed outlet-side flow passages 70H.sub.out in the state where they are penetrated, and has protrusion parts 70WP in the unclosed inlet-side flow passages 70H.sub.in.

[0044] The composition of the ceramic raw material only has to be one giving porous ceramics after firing. For example, it can contain the ceramic raw material, an organic binder, a pore-forming agent, a solvent and an additive that is added as needed.

[0045] The ceramic raw material is powder containing elements constituting the ceramics. The binder can be an organic binder, and examples thereof can include celluloses such as methylcellulose, carboxymethylcellulose, hydroxyalkylmethylcellulose and sodium carboxymethylcellulose, alcohols such as polyvinyl alcohol, and sulfonate salts of lignins. Examples of the additive include lubricants, plasticizers and dispersants.

[0046] Next, as shown in FIG. 6, the outlet-side flow passages 70H.sub.out are closed on the inlet-side end face 10E.sub.in of the obtained unfired honeycomb compact 100. Specifically, a closing jig 400 having many triangular pyramidal projections 410a is prepared. Then, the closing jig 400 is moved such that the projections 410a enter the inlet-side flow passages 70H.sub.in. In this way, as shown in FIG. 7, the partition walls of the inlet-side flow passages 70H.sub.in are deformed, and the cross-section areas of the flow passages are enlarged, and meanwhile, the cross-section areas of the outlet-side flow passages 70H.sub.out are reduced. Then, eventually, as shown in portions (a) and (b) of FIG. 4, the cross-section shapes of the inlet-side flow passages 70H.sub.in become triangular, the partition walls are completely crimped together at the outlet-side flow passages 70H.sub.out, and the outlet-side flow passages 70H.sub.out are closed. Namely, the outlet-side flow passages 70H.sub.out are closed on the inlet-side end face 10E.sub.in. Notably, vibration or ultrasonic waves may be given to the closing jig 400.

[0047] Next, likewise, the inlet-side flow passages 70H.sub.in on the outlet-side end face 10E.sub.out are closed with another closing jig. The projections, of the closing jig, which are inserted into the outlet-side flow passages 70H.sub.out can be made hexagonal pyramidal. After that, after dried as needed, the honeycomb compact 100 both end faces of which have been closed is fired, and thereby, the honeycomb filter 100 according to the embodiment is obtained.

[0048] According to the embodiment, the protrusion part WP is provided between a pair of partition walls W of the inlet-side flow passage 70H.sub.in. Due to this, when closing the outlet-side flow passage 70H.sub.out by deforming the partition walls so as to enlarge the cross-section area of the inlet-side flow passage 70H.sub.in, the partition wall W, in particular, the corner part before deformation hardly suffers cracks. Accordingly, a honeycomb filter with less defects can be manufactured.

Second Embodiment

[0049] Next, referring to FIG. 8 to FIG. 10, a honeycomb filter 102 according to a second embodiment is described. Description of the points same as those in the first embodiment is omitted. FIG. 8 shows a cross-section in the axial-directional center part of the honeycomb filter 102 according to the embodiment. Different from the honeycomb filter 100 according to the first embodiment, in this embodiment, the inlet-side flow passages 70H.sub.in and the outlet-side flow passages 70H.sub.out are regularly arranged in such a way that one inlet-side flow passage 70H.sub.in is adjacent to four other inlet-side flow passages 70H.sub.in and is adjacent to two outlet-side flow passages 70H.sub.out. One outlet-side flow passage 70H.sub.out is adjacent to six inlet-side flow passages 70H.sub.in and is not adjacent to the other outlet-side flow passages 70H.sub.out. Accordingly, each flow passage is adjacent to totally six flow passages.

[0050] In the inlet-side flow passage 70H.sub.in, in each corner part made between a pair of partition walls W, the protrusion part WP protruding toward the interior of the inlet-side flow passage 70H.sub.in is formed. Herein, in the embodiment, the protrusion part WP is provided in the corner part between a partition wall Wii that separates the inlet-side flow passage 70H.sub.in and the inlet-side flow passage 70H.sub.in from each other and a partition wall Wio that separates the inlet-side flow passage 70H.sub.in and the outlet-side flow passage 70H.sub.out from each other, and a protrusion part WP is not provided in the corner part between the partition wall Wii and the partition wall Wii. Accordingly, the cross-section shape of the inlet-side flow passage 70H.sub.in has a shape in which four vertices other than two opposite vertices are caused to protrude toward the inside.

[0051] Next, referring to FIG. 9, the inlet-side structure is presented. On the inlet-side end face 10E.sub.in, the cross-section area of the inlet-side flow passage 70H.sub.in is made larger than that in the central part in the axial direction. On the other hand, the cross-section area of the outlet-side flow passage 70H.sub.out is made 0. Specifically, the substantial hexagon which is the cross-section shape of each inlet-side flow passage 70H.sub.in in the axial-directional center part is enlarged so as to become substantially rhombic by two opposite sides thereof being enlarged, the vertices of each rhombus reach the centers of the outlet-side flow passages 70H.sub.out, and in this way, the outlet-side flow passage 70H.sub.out is closed.

[0052] Next, referring to FIG. 10, the outlet-side structure is presented. On the outlet-side end face 10E.sub.out, the cross-section area of the outlet-side flow passage 70H.sub.out is made larger than that in the central part in the axial direction. On the other hand, the cross-section area of the inlet-side flow passage 70H.sub.in is made 0. Specifically, the hexagon which is the cross-section shape of the outlet-side flow passage 70H.sub.out in the axial-directional center part is enlarged as it is, the vertices of each hexagon reach the centers of the inlet-side flow passages 70H.sub.in, and in this way, the inlet-side flow passage 70H.sub.in is closed.

[0053] For such a honeycomb filter, after molding a honeycomb compact having the protrusion parts WP in the shapes of FIG. 8, the closing only has to be performed similarly to the first embodiment.

[0054] Also in the embodiment, the protrusion parts WP can suppress cracks from occurring.

Third Embodiment

[0055] Next, referring to FIG. 11, a honeycomb filter 104 according to a third embodiment is described. Description of the points same as those in the first embodiment is omitted. FIG. 11 shows a cross-section in the axial-directional center part of the honeycomb filter 104 according to the embodiment. Different from the honeycomb filter 100 according to the first embodiment, in this embodiment, the inlet-side flow passages 70H.sub.in and the outlet-side flow passages 70H.sub.out are regularly arranged in such a way that one inlet-side flow passage 70H.sub.in is adjacent to four other inlet-side flow passages 70H.sub.in and is adjacent to four outlet-side flow passages 70H.sub.out. One outlet-side flow passage 70H.sub.out is adjacent to four inlet-side flow passages 70H.sub.in and is not adjacent to the other outlet-side flow passages 70H.sub.out.

[0056] The outlet-side flow passage 70H.sub.out is formed of four partition walls W, and its cross-section shape is substantially tetragonal. The inlet-side flow passage 70H.sub.in is formed of eight partition walls W. In the inlet-side flow passage 70H.sub.in, in each corner part C made between a pair of partition walls W, the protrusion part WP protruding toward the interior of the inlet-side flow passage 70H.sub.in is formed. Accordingly, the cross-section shape of the inlet-side flow passage 70H.sub.in has a shape in which the vertices of the octagon are caused to protrude toward the inside.

[0057] Illustration omitted, on the inlet-side end face, the cross-section area of the outlet-side flow passage 70H.sub.out is enlarged into a tetragon whose vertices are present in respective four inlet-side flow passages 70H.sub.in such that the inlet-side flow passage 70H.sub.in is closed. Moreover, on the outlet-side end face, the cross-section area of the inlet-side flow passage 70H.sub.in is enlarged into a tetragon whose vertices are present in respective four outlet-side flow passages 70H.sub.out such that the outlet-side flow passage 70H.sub.out is closed.

[0058] Also in the embodiment, the protrusion parts WP can suppress cracks from occurring.

Fourth Embodiment

[0059] Next, referring to FIG. 12, a honeycomb filter 105 according to a fourth embodiment is described. Description of the points same as those in the first embodiment is omitted. FIG. 12 shows an expanded cross-section in the axial-directional center part of the honeycomb filter 105 according to the embodiment. Different from the honeycomb filter 100 according to the first embodiment, in this embodiment, the partition wall W is not flat plate-shaped but the cross-section shape of the face on the inlet-side flow passage 70H.sub.in side is a waved plate. A protrusion part WPa or a protrusion part WPb is provided in the corner part C made between an adjacent pair of partition walls W. Each of a protrusion height HTa from the line connecting both ends of the bottom part of the protrusion part WPa and a protrusion height HTb from the line connecting both ends of the bottom part of the protrusion part WPb can be 0.04 to 0.20 mm and they can be different from each other. Each of these protrusion part WPa and protrusion part WPb protrudes toward the interior of the inlet-side flow passage 70H.sub.in and extends in the axial direction. Moreover, the partition wall W has a protrusion part WP3 (third protrusion part) that protrudes toward the interior of the inlet-side flow passage 70H.sub.in and extends in the axial direction in a central part of the partition wall W.

[0060] Also in the embodiment, cracks can be suppressed from occurring by the protrusion part WPa and the protrusion part WPb.

[0061] Notably, the present invention is not limited to the aforementioned embodiments but various modification modes are possible.

[0062] For example, the arrangement of the protrusion parts WP can be properly changed. It is preferable that the protrusion part WP be provided in the corner part formed between the partition wall separating the outlet-side flow passage 70H.sub.out and the inlet-side flow passage 70H.sub.in and another partition wall (for example, which may be any of the partition wall separating the outlet-side flow passage 70H.sub.out and the inlet-side flow passage 70H.sub.in, the partition wall separating the outlet-side flow passages 70H.sub.out, and the partition wall separating the inlet-side flow passages 70H.sub.in). This is because the partition wall separating the outlet-side flow passage 70H.sub.out and the inlet-side flow passage 70H.sub.in is deformed in closing, and therefore, stress tends to be exerted on that corner part.

[0063] Moreover, while in the aforementioned embodiments, the protrusion parts WP are provided only in the inlet-side flow passages 70H.sub.in, for example, as presented by broken lines in FIG. 3 and FIG. 11, a protrusion part (second protrusion part) WP2 that protrudes toward the interior of the outlet-side flow passage 70H.sub.out and extends in the axial direction may be provided in the corner part between the partition walls in the outlet-side flow passage 70H.sub.out. In this case, when the inlet-side flow passages 70H.sub.in are closed by deforming the outlet-side flow passages 70H.sub.out, cracks can be suppressed.

[0064] Moreover, as shown in FIG. 3, FIG. 8, FIG. 11 and FIG. 12, in the central part of at least one of the inlet-side flow passages (first flow passages) in the axial direction, at least one of the partition walls W can also have the protrusion part WP3 (third protrusion part) that protrudes toward the interior of the inlet-side flow passage or the outlet-side flow passage (second flow passage) and extends in the axial direction in a central part of the partition wall W. In this case, cracks when the central part of the partition wall is deformed can be suppressed.

[0065] Moreover, the arrangement of the inlet-side flow passages and the outlet-side flow passages, that is, the number of flow passages adjacent to each flow passage is also not limited to those in the aforementioned embodiment. Notably, in the present specification, two flow passages being adjacent to each other can mean that two flow passages are separated via one partition wall in the thickness direction of the partition wall. Two flow passages that are positioned in diagonal relation in a so-called square flow passage arrangement are not flow passages being adjacent to each other.

[0066] Moreover, the cross-section shape of the flow passage is also not specially limited to those in the aforementioned embodiments but it only has to be a shape with corner parts. Moreover, the cross-section shape of the protrusion part is also not limited to a shape having a part of a circle, that is, an arc, but it may be a shape having a part of a polygon such as a triangle and a tetragon or may also be a shape having a part of an ellipsoid.

[0067] Furthermore, the shape of appearance of the filter may not be a cylindrical body but, for example, may also be tetragonal prismatic. The density of cells can be made, for example, 200 to 400 cpsi.

REFERENCE SIGNS LIST

[0068] 70H.sub.in Inlet-side flow passage (first flow passage) [0069] 70H.sub.out Outlet-side flow passage (second flow passage) [0070] WP Protrusion part (first protrusion part, second protrusion part) [0071] 10 Cylindrical body (columnar body) [0072] W Partition wall [0073] C Corner part [0074] CP Central part [0075] 100 Honeycomb filter